RUSTED FUEL LINES- GARAGE CHECKED STRONG FUEL SMELL AND DISCOVERED RUSTED FUEL FILLER AND LINES
2004 Chevrolet Trailblazer Ext
Owner reports · Recalls · Investigations
Limited comparison data
There is not enough comparable history to draw a useful model-year comparison.
About this comparison →How this year compares
Owner complaints by model year
Compare all Trailblazer Ext years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
216 reports with mileage · 45 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Electrical System. Review the 145 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Fuel System, Gasoline. Review the 29 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Power Train. Review the 17 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
Fuel/propulsion System complaints
9 reportsTHE INLET CHECK VALVE IS FRACTURED AND CHEVY WILL NOT DO ANY REPAIRS DUE TO THE MILEAGE BEING OVER 150000
MY FUEL TANK HAS A HOLE IN IT. I HAVE FILED A PREVIOUS COMPLAINT WITH NHTSA AND ALSO WITH GM. AN NHTSA WORKER HELPED ME A LOT AND WHEN I CALLED GM AND CHEVY BACK I WAS TOLD SEVERAL TIMES SOMEONE WOULD GET BACK IN TOUCH WITH ME. I HAVE TRIED TO GET IT FIXED BUT NO ONE IS ABLE TO HELP. I HAVE TRIED MANY PLACES FOR USED FUEL TANKS …
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MY FUEL TANK HAS A HOLE IN IT. I HAVE FILED A PREVIOUS COMPLAINT WITH NHTSA AND ALSO WITH GM. AN NHTSA WORKER HELPED ME A LOT AND WHEN I CALLED GM AND CHEVY BACK I WAS TOLD SEVERAL TIMES SOMEONE WOULD GET BACK IN TOUCH WITH ME. I HAVE TRIED TO GET IT FIXED BUT NO ONE IS ABLE TO HELP. I HAVE TRIED MANY PLACES FOR USED FUEL TANKS BUT EVERYONE SAYS THAT THE ENVOYS AND TRAILBLAZERS THAT THEY HAVE ALL HAVE THE SAME EXACT ISSUE. I CANNOT GET ANY HELP FROM GM OR CHEVY.
TL* THE CONTACT OWNS A 2004 CHEVROLET TRAILBLAZER EXT. THE CONTACT STATED HE BEGAN TO SMELL FUEL INSIDE OF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION WHERE THEY STATED THAT THE FUEL TANK NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS…
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TL* THE CONTACT OWNS A 2004 CHEVROLET TRAILBLAZER EXT. THE CONTACT STATED HE BEGAN TO SMELL FUEL INSIDE OF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION WHERE THEY STATED THAT THE FUEL TANK NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 86,000. THE VIN WAS UNAVAILABLE.
SEVERAL MONTHS THE SMELL OF GASOLINE WAS VERY STRONG IN THE INTERIOR OF MY SUV. I DROVE IT ABOUT FIVE MILES FROM MY HOME WITH A FULL TANK, AS I DROVE IT THE SMELL BECAME MUCH STRONG, WHEN I REACHED MY DESTINATION A PERSON POINTED OUT TO ME THAT GASOLINE WAS POURING FROM THE BOTTOM OF MY TRUCK LIKE A WATER HOSE. I IMMEDIATELY R…
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SEVERAL MONTHS THE SMELL OF GASOLINE WAS VERY STRONG IN THE INTERIOR OF MY SUV. I DROVE IT ABOUT FIVE MILES FROM MY HOME WITH A FULL TANK, AS I DROVE IT THE SMELL BECAME MUCH STRONG, WHEN I REACHED MY DESTINATION A PERSON POINTED OUT TO ME THAT GASOLINE WAS POURING FROM THE BOTTOM OF MY TRUCK LIKE A WATER HOSE. I IMMEDIATELY RETURNED HOME TO PARK THE VEHICLE. AS I TRIED TO RECALL WHAT MAY HAVE OCCURRED, I REMEMBERED THAT TWO DAYS PRIOR TO THE INCIDENT I GOT AN OIL CHANGE; I ASSUMED THAT MAYBE THEY HAD DONE SOMETHING TO AGGRAVATE AN ALREADY EXISTING PROBLEM. AFTER THEY REVIEWED THEIR WORK, I WAS TOLD IT WAS A MANUFACTURES PROBLEM. I LATER TOOK THE VEHICLE TO WOLF CHEVROLET (NOW DEFUNCT DEALER). A DIAGNOSTIC WAS DONE AND IT WAS DETERMINED THAT THE GAS TANK MUST BE REPLACED WITH A COST OF $1192. AND THE SUV IS CONSIDERED "TOO DANGEROUS TO DRIVE". I THEN WENT TO ANOTHER AUTOMOTIVE ESTABLISHMENT AND WAS GIVEN THE SAME DIAGNOSIS. AFTER TAKING IN CONSIDERATION BOTH ESTIMATES AND MY NEED FOR TRANSPORTATION, I CONTACTED GM AND SPOKE WITH A CUSTOMER SERVICE REPRESENTATIVE WHO INFORMED ME THAT I NEEDED TO TAKE THE VEHICLE TO A CERTIFIED GM DEALER. I TOOK THE VEHICLE TO LOU BACHRODT IN CHERRY VALLEY, ILLINOIS AND WAS GIVEN THE SAME DIAGNOSIS. AFTERI RELAYED THE IINFORMATION TO THE GM REP, HE SAID THAT DUE TO THE AGE OF THE VEHICLE AND THE MILEAGE, GM WOULD NOT BE ABLE TO OFFER ME ANY COMPENSATION. HE SUGGESTED I PHONE LOU BACHRODT AND SEE IF THEY COULD ASSIST ME IN THE COST, THE SERVICE TECHNICIAN GAVE ME THE SAME STATEMENT; AGE AND MILEAGE. I AM WRITING BECAUSE FROM ALL INDICATIONS THIS PROBLEM IS NOT ONLY PREVALENT IN MY SUV BUT AFTER DOING RESEARCH, SEVERAL 2004 CHEVROLET TRAILBLAZER OWNERS HAVE EXPERIENCED SIMILAR PROBLEMS. IT IS MY BELIEF THAT CHEVROLET GM SHOULD TAKE OWNERSHIP FOR ALL OR SOME OF THIS PROBLEM. *TR
DUE TO A SERVICE ENGINE SOON WARNING LIGHT AND SMELLING GAS INSIDE MY VEHICLE, I TOOK MY VEHICLE TO MY LOCAL MECHANIC. HE STATED THERE WAS A CRACK IN THE NECK OF MY FUEL TANK. THE TANK NEEDS TO BE REPLACED. HE ALSO STATED THAT THIS IS A COMMON PROBLEM WITH TRAILBLAZERS. I LOOKED UP ANY RECALLS. FOUND SPECIAL COVERAGE ADJUSTMENT …
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DUE TO A SERVICE ENGINE SOON WARNING LIGHT AND SMELLING GAS INSIDE MY VEHICLE, I TOOK MY VEHICLE TO MY LOCAL MECHANIC. HE STATED THERE WAS A CRACK IN THE NECK OF MY FUEL TANK. THE TANK NEEDS TO BE REPLACED. HE ALSO STATED THAT THIS IS A COMMON PROBLEM WITH TRAILBLAZERS. I LOOKED UP ANY RECALLS. FOUND SPECIAL COVERAGE ADJUSTMENT - FUEL TANK INLET CHECK VALVE FRACTURE#07099A. I CALLED A LOCAL DEALER WHO CONFIRMED THAT WAS RIGHT. HOWEVER MY VIN # DOES NOT FALL UNDER VIN #'S LISTED. THE DEALER CALLED A LOCAL GM REP. AND I WAS OFFERED 40% COVERED BY GM MEANING I WOULD HAVE TO COVER THE OTHER 60%. I DO NOT UNDERSTAND WHY ONLY SOME VIN#'S ARE IN THIS AND NOT ALL OF THEM. IT SEEMS THAT THIS A PROBLEM THAT IS VERY COMMON IN THESE TRAILBLAZERS. I DO NOT FEEL SAFE DRIVING MY FAMILY OF 5 AROUND IN THIS TRAILBLAZER WITH A FRACTURE FUEL TANK INLET CHECK VALVE AND THE STRONG SMELL OF GAS IN THE TRUCK AND RISK OF FIRE FROM GAS LEAKING OUT. THIS SHOULD BE A RECALL ITEM SO THAT THOSE OF US THAT HAVE TRAILBLAZERS NOT WITH IN THE VIN #'S COVERED CAN GET THIS FIXED AND BE SAFE. CHEVROLET/GM SHOULD STEP UP AND MAKE THIS A RECALL THIS IS A HUGE SAFETY ISSUE. *TR
DUE TO A SERVICE ENGINE SOON WARNING LIGHT AND SMELLING GAS INSIDE MY VEHICLE, I TOOK MY VEHICLE TO MY LOCAL MECHANIC. HE STATED THERE WAS A CRACK IN THE NECK OF MY FUEL TANK. THE TANK NEEDS TO BE REPLACED. HE ALSO STATED THAT THIS IS A COMMON PROBLEM WITH TRAILBLAZERS. I THEN TOOK THE VEHICLE TO THE GM DEALER WHERE IT WAS PURCH…
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DUE TO A SERVICE ENGINE SOON WARNING LIGHT AND SMELLING GAS INSIDE MY VEHICLE, I TOOK MY VEHICLE TO MY LOCAL MECHANIC. HE STATED THERE WAS A CRACK IN THE NECK OF MY FUEL TANK. THE TANK NEEDS TO BE REPLACED. HE ALSO STATED THAT THIS IS A COMMON PROBLEM WITH TRAILBLAZERS. I THEN TOOK THE VEHICLE TO THE GM DEALER WHERE IT WAS PURCHASED. THEIR INITIAL DIAGNOSIS WAS THE FUEL CAP NEEDED TO BE REPLACED. AT THAT POINT I ASKED THEM TO CHECK FOR A CRACK. THEY DID AND VERIFIED THERE IS A CRACK. I MENTIONED GM CAMPAIGN 07099A - A RECALL FOR TRAILBLAZER EXT'S TO REMEDY THIS PROBLEM BY REPLACING THE FUEL TANK AT NO CHARGE. UNFORTUNATELY, THIS RECALL ONLY AFFECTED CERTAIN VIN #'S AND MINE IS NOT WITHIN THE AFFECTED NUMBER RANGE. I BELIEVE THIS IS A VERY DANGEROUS SAFETY DEFECT THAT SHOULD BE REMEDIED BY THE DEALER AT NO COST TO ME. THE DEALER OFFERED A 50/50 RESOLUTION WHICH TO ME ONLY SERVES TO PROVE THEIR CULPABILITY IN THE MATTER. I DO NOT FEEL SAFE DRIVING THE VEHICLE AND AM VERY CONCERNED FOR MY SAFETY AND THE SAFETY OF MY TWO YEAR OLD GRANDDAUGHTER WHOM I REGULARLY TRANSPORT IN THIS VEHICLE. *TR
I WAS DRIVING DOWN THE ROAD WHEN I RAN OUT OF GAS. IT STILL SHOWED OVER 100 MILES LEFT ON THE GAUGE. THAT WAS ABOUT 3 MONTHS AFTER I PURCHASED THE VEHICLE. ABOUT TWO MONTHS LATER, I HAD THE SAME PROBLEM. I STARTED KEEPING THE GAS ON 3/4 OF A TANK AT ALL TIMES TO MAKE SURE THERE WAS FUEL IN IT. THE PROBLEM KEPT HAPPENING. T…
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I WAS DRIVING DOWN THE ROAD WHEN I RAN OUT OF GAS. IT STILL SHOWED OVER 100 MILES LEFT ON THE GAUGE. THAT WAS ABOUT 3 MONTHS AFTER I PURCHASED THE VEHICLE. ABOUT TWO MONTHS LATER, I HAD THE SAME PROBLEM. I STARTED KEEPING THE GAS ON 3/4 OF A TANK AT ALL TIMES TO MAKE SURE THERE WAS FUEL IN IT. THE PROBLEM KEPT HAPPENING. TODAY, IT WAS ON 200+ MILES AND I RAN OUT. THIS IS RIDICULOUS! DO I REALLY HAVE TO KEEP TRACK OF HOW MANY MILES I PUT ON IT SO I KNOW WHEN I NEED TO REFILL? *TR
I JUST GASED THE CHEVROLET TRAILBLAZER AND WAS DRIVING DOWN THE ROAD AND WE COULD SMELL GAS DID NOT THINK MUCH OF IT BECAUSE WE JUST GOT GAS THEN THE CHECK ENGINE LIGHT CAME ON IT WAS A PO442 CODE EVAPORATIVE EMISSION CONTROL SMALL LEAK DETECTED SO I HAVE BEEN SMELLING GAS OFF AND ON AND KEEP GETTING THE PO442 CODE. SO I GO BUY …
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I JUST GASED THE CHEVROLET TRAILBLAZER AND WAS DRIVING DOWN THE ROAD AND WE COULD SMELL GAS DID NOT THINK MUCH OF IT BECAUSE WE JUST GOT GAS THEN THE CHECK ENGINE LIGHT CAME ON IT WAS A PO442 CODE EVAPORATIVE EMISSION CONTROL SMALL LEAK DETECTED SO I HAVE BEEN SMELLING GAS OFF AND ON AND KEEP GETTING THE PO442 CODE. SO I GO BUY A VENT VALVE SOLENOID AND PUT IT ON CLEAR THE CODE I NOTICE GAS AROUND THE INTAKE PIPE ON THE GAS TANK SO I TAKE A CLOSER LOOK AND ITS BROKE HALF WAY AROUND THE FILLER NECK AND THIS IS A RECALL ON CERTAIN VIN #S BUT MINE IS NOT INCLUDED IN THIS RECALL I THINK IT SHOULD BE WHEN YOU ARE DEALING WITH FUEL AND THE AMOUNT OF FUEL THAT CAN LEAK OUT THIS CAN BE A FIRE HAZARD FOR SURE I THINK GM NEEDS TO STEP UP AND TAKE CARE OF THIS PROBLEM ON ALL VEHICLES THAT HAVE THIS PROBLEM INSTEAD OF PICKING AN CHOOSING CERTAIN VIN #S. *TR
Official recalls
104V527000 · Exterior Lighting:brake Lights
Nov 1, 2004
ON CERTAIN SPORT UTILITY VEHICLES, VIBRATION AND HEAT MAY CAUSE THE TAIL LAMP/STOP LAMP BULB TO LOOSEN IN ITS SOCKET. IF THIS OCCURS, THE BULB MAY FLICKER AND EVENTUALLY BECOME INOPERATIVE.
Consequence & remedy
Consequence: AN INOPERATIVE BRAKE LAMP WILL NOT CONVEY THE DRIVER'S INTENTION OF STOPPING TO DRIVERS IN FOLLOWING VEHICLES, AND AN INOPERATIVE REAR TURN SIGNAL LAMP WILL NOT CONVEY THE DRIVER'S INTENTION TO TURN TO DRIVERS IN FOLLOWING VEHICLES. BOTH OF THESE FAILURES CAN INCREASE THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT THE TAIL LAMP/STOP LAMP ASSEMBLIES, AND IF NECESSARY, REPLACE THEM. THE RECALL BEGAN ON NOVEMBER 22, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438, OLDSMOBILE AT 1-800-630-6537, BUICK AT 1-866-608-8080, OR GMC AT 1-866-996-9463.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
3RQ17002 · Loss Of Headlights
Opened Apr 24, 2017 · Closed Mar 29, 2021
Status: closed (inferred from source dates) · Exterior Lighting:headlights
The subject vehicles are model year (MY) 2002-2009 Chevrolet Trailblazer, GMC Envoy, 2004-2007 Buick Rainier, 2003-2008 Isuzu Ascender, 2005-2009 Saab 9-7X, 2002-2004 Oldsmobile Bravada, 2003-2006 Chevrolet SSR, 2005-2009 Buick Lacrosse, and 2006-2008 Pontiac Grand Prix. This scope includes the Trailblazer/Envoy variants: 2002-2006 Envoy XL/Trailblazer EXT and 2004-2005 Envoy XUV. The original scope of this investigation was expanded to include all vehicles equipped with the subject Headlight Driver Module (HDM). The focus of the investigation was to determine whether actions performed by General Motors adequately addressed any unreasonable risk to motor vehicle safety in the subject vehicles concerning the headlights and the HDM that controls them.Under normal electrical load and environmental conditions, the HDM can overheat inside the Underhood Electrical Center (UEC). This can cause the module to fail and result in a simultaneous loss of both low beam headlights and both daytime running lights (DRLs), often with no warning or prior detectability to the driver. This failure can be intermittent or permanent. No other exterior lights are affected. High beams, turn signals, brake lights, and reverse lights are still operational.General Motors addressed this issue with 2 recalls (14V755 & 15V519) and a special coverage program (N172091910). In view of the recalls and special coverage program implemented by GM and the vehicle high beams continuing to operate, ODI has tentatively concluded that the actions taken by GM mitigate any unreasonable risk to safety posed by HDM failure in the subject vehicles.Accordingly, the investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The agency reserves the right to take additional action if warranted by new circumstances.The ODI reports cited above are available for review online at NHTSA.gov under the identification numbers in the attached document.
EA07009 · Fuel Pump Module Leaks Gasoline
Opened Jul 10, 2007 · Closed Aug 28, 2008
Status: closed (inferred from source dates) · Fuel System, Gasoline:delivery:fuel Pump
DURING THE COURSE OF THIS EA INVESTIGATION, ODI OBSERVED THAT THE MAJORITY OF THE COMPLAINTS (88%) AND WARRANTY CLAIMS (94%) WERE REPORTED FOR VEHICLES THAT ARE REGISTERED FOR USE IN THE SALT BELT REGION OF THE US.THIS AREA INCLUDES 20 STATES IN THE NORTHEAST, MID ATLANTIC AND THE MIDWEST REGIONS AND THE DISTRICT OF COLUMBIA.CONSUMERS IN THE SALT BELT REGION REPORTED TO ODI THAT THEY COULD SMELL FUEL VAPORS IN THEIR VEHICLES WHILE DRIVING.UPON FURTHER EXAMINATION OF THEIR VEHICLES, THEY DISCOVERED THAT FUEL VAPORS WERE COMING OUT OF THE TOP OF THE FUEL TANK. THIS CONDITION IS CAUSED BY CORROSION OF THE RETURN AND SENDER LINES OF THE FUEL PUMP MODULE.WATER AND ROAD SALT COLLECT ON TOP OF THE FUEL PUMP LEADING TO SMALL PINHOLES APPEARING ON THE FUEL LINES.FUEL MAY LEAK AND COLLECT ON TOP OF THE MODULE AND/OR SPILL ONTO THE GROUND.THE DATA EVALUATED UNDER THIS INVESTIGATION REFLECT A RELATIVELY LOW FREQUENCY OF OCCURRENCE THAT LARGELY ARISES IN SALT BELT STATES.GM HAS EXTENDED THE WARRANTY ON THE SUBJECT COMPONENT TO TEN YEARS OR 120,000 MILES.FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED AT THIS TIME; ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.FOR ADDITIONAL INFORMATION SELECT DOCUMENT SEARCH.
EA04021 · Brake Lamp Failure
Opened Aug 3, 2004 · Closed Nov 4, 2004
Status: closed (inferred from source dates) · Exterior Lighting:brake Lights
GM STATES THAT SOME BRAKE/TAIL LAMP BULBS CAN PREMATURELY BECOME INOPERATIVE DUE TO MALFUNCTIONING BRAKE/TAIL LAMP SOCKETS.ON MARCH 2, 2004, GM INITIATED A 6-YEAR/72,000 MILE SPECIAL POLICY FOR 989,487 SUBJECT VEHICLES TO INSPECT AND REPLACE THE REAR BRAKE/TAIL LAMP BULB SOCKET ASSEMBLIES.ON APRIL 4, 2004, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE04-032) BASED ON CONSUMER COMPLAINTS ALLEGING BRAKE LIGHTS NOT OPERATING WHEN THE BRAKE PEDAL IS DEPRESSED.ON AUGUST 3, 2004 ODI UPGRADED PE04-032 TO AN ENGINEERING ANALYSIS (EA04-021).BY LETTER DATED OCTOBER 27, 2004 GM NOTIFIED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA # 04V527) COVERING SUBJECT VEHICLES THAT WERE NOT ALREADY REPAIRED UNDER GM'S SPECIAL POLICY.MY 2004 SUBJECT VEHICLES BUILT AFTER AUGUST 8, 2003 CONTAIN IMPROVED BRAKE LAMP ASSEMBLIES AND ARE NOT INCLUDED IN THE RECALL.GM DEALERS WILL INSTALL THE IMPROVED BRAKE LAMP ASSEMBLY ON SUBJECT VEHICLES BUILT ON AUGUST 8, 2003 AND EARLIER.THE ACTION TAKEN BY GM IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
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